Mechanical and tribological properties of a WC-based HVOF spray coated brake disc

Abstract

Thermally sprayed WC-based coating systems are generally used to increase engineering components’ wear resistance. This research presents the results of a comparative study conducted to examine the tribological characteristics of a new brake disc created with thermal sprayed WC-10Co4Cr coating. This study implemented braking tests on the WC-10Co4Cr coated brake disc against commercial friction material on a laboratory scale disc-pad tester and compared the findings with the reference disc. The coating system was created with a high velocity oxygen-fuel spraying on a cast iron disc. The braking tests followed the sections of the SAE-J2430 test procedure. The microstructure, phase composition and properties of the coating were characterized by SEM/EDS, XRD and Vickers microstructure. The effect of carbide coating on the friction and wear behaviour of the tribological system was examined. The WC-10Co4Cr coating has increased the hardness by 3 times with a thickness of 300 μm compared to the cast iron surface. The amount of wear in the coated disc (CD) was reduced by about 85% compared to the reference disc (BD). The coefficient of frictions of BD and CD was found to be in the range of 0.43–0.61 and 0.47–0.62, respectively. The inclusion of hard phases (WC and W2C) in the disc coating played an important role in improving the sliding wear resistance by maintaining the coefficient of friction of the brake disc at an acceptable level. In brief, carbide coating could be claimed to be promising for challenging braking implementations.

Microstructure and Wear Resistance of Fe3Al Coating on GCI Prepared by Direct Energy Deposition (DED)

“…For instance, carbonceramic composites have been established as an alternative to traditional brake disc materials since they display reduced wear rates and PM emission [7][8][9], However, because of the sophisticated production methods and unique features, these kinds of discs usually come with a higher price and for specific luxury cars. The application of coatings and disc surface treatments has also been investigated to reduce wear and PM emissions of brake discs [2,[10][11][12][13][14].…”

“…Numerous studies have primarily focused on the application of the coating for improving the wear resistance of brake discs [13,14,17,25], frequently neglecting the critical environmental considerations associated with the selection of coating materials. Considering the promising characteristics of Fe3Al and its potential as a coating material, this study aims to investigate the microstructure and wear resistance of Fe3Al coating on GCI prepared via DED.…”

Determination of wear resistance of nickel-carbide alloy coating by atmospheric plasma spray technique on 30MnB5 alloy steel used in cultivator blades

“…Therefore, a protective coating on the surface can be a practical solution. Thermal spraying is the most common surface technology for applying wear protection coatings [7,[18][19][20][21][22][23][24][25][26], with atmospheric plasma spraying (APS) being the most practical of the thermal spraying techniques [17,27].…”

Microstructure and Wear Resistance of Fe3Al Coating on Grey Cast Iron Prepared via Direct Energy Deposition

“…For instance, carbon-ceramic composites have been established as an alternative to traditional brake disc materials since they display reduced wear rates and PM emission levels [6][7][8], However, because of the sophisticated production methods and unique features, these kinds of discs usually come with a higher price and are used for specific luxury cars. The application of coatings and disc surface treatments has also been investigated to reduce the wear and PM emissions of brake discs [2,[9][10][11][12].…”

“…Numerous studies have primarily focused on the application of this coating for improving the wear resistance of brake discs [11,12,15], frequently neglecting the critical environmental considerations associated with the selection of coating materials. Considering the promising characteristics of Fe 3 Al and its potential as a coating material, this study aims to investigate the microstructure and wear resistance of an Fe 3 Al coating on GCI prepared via DED.…”